Apparatus for fabricating door assemblies



W. J. ZENNER 3,297,065

APPARATUS FOR FABRICATING DOOR ASSEMBLIES Jan. 10, 1967 '7 Sheets-Sheat. 1

Filed Jan. 21, 1965 INVENTOR.

mi 7% V Jan. 10, 1967 V w. J. ZENNER I 3,297,065

INVENTOR. WALTER J. ZE/V/VER BY M w W FHHEA Jan. 10, 1967 w. J. ZENNERAPPARATUS FOR FABRICATING DOOR ASSEMBLIES '7 Sheets-Sheet 5 Filed Jan.21, 1965 MN wk Wu K ,wvE/vmR WALTER J, ZE/V/VE/P Jan. 10, 1967 w. J.ZENNER APPARATUS FOR FABRICATING DOOR ASSEMBLIES Fil ed Jan. 21; 1965 '7Sheets-Sheet 4 mmw m3 1 :5 5 m #S QT? K m&

INVENTOR. W/JL TER J. ZE/V/VEH Jan. 10, 1967 w. J. ZENNER APPARATUS FORFABRICATING DOOR ASSEMBLIES Filed Jan. 21, 1965 'T Sheets-Sheet 5 24 INIII M 5 R mm H W EA V F WZ VJ V m m W B 2 7 I12 2 Jan. 10,1967 w. J.ZENNER APPARATUS FOR FABRICATING DOOR-ASSEMBLIES 7 Sheets-Sheet 6INVENTOR WALTER J ZEN/V55 Filed Jan. 21, 1965 wmwmL Jan. 10, 1967 w. J.ZENNER APPARATUS FOR FABRICATING DOOR ASSEMBLIES Filed Jan. 21, 1965 7Sheets-Sheet v' F1 /6 507 308 LI 275 INVENTOR. WALTER J- ZE/V/VER ;:385EMERG. STOP Unit atent Patented Jan. 1%, i957 nice Walter .i. Zenner,i776 Sherwood Ave, Des liaines, it'll. @3016 Filed .l an. 21, 1965, her.No. 426,974) iii Claims. ill. lad-2'7) This invention relates to a newand improved method of manufacturing door assemblies and to a new andimproved automatic routing and drilling machine for fabricating doorassemblies. More specifically, the method and the automatic machine ofthe invention provide improved precision and versatility in routing anddrilling a door and a pair of jambs, in a single operation, to affordthe requisite receptacles for the door hinges and for a completelockset.

The hanging of doors has traditionally been one of the more tliffiCLllland demanding tasks of the finish carpenter. Working by hand, thecarpenter cuts into one longitudinal edge of the door to afford shallowreceptacles for three hinge plates. Matching receptacles must beprovided in the door jamb upon which the door is hung. Either before orafter the door is hung, a lockset is mounted in the door. A boltreceptacle is then cut, in the other jamb, on the opposite side of thedoor opening from the jamb on which the door is hung, and a strikerplate is mounted on the receptacle. This is a time-consuming andexacting job and requires a skilled carpenter if the door is to hang andswing properly.

More recently, efforts have been directed toward automation of thefabrication of door assemblies to eliminate the necessity for theprecision on-the-job carpenter work previously entailed in the hangingof doors. At least one commercial machine has been produced that routsthe hinge edge of the door to afford a series of hinge receptacles,routs the hinge jamb to provide corresponding hinge receptacles therein,drills the door for a lockset, and drills the lock jamb to provide abolt receptacle and striker plate receptacle. Such equipment, asheretofore known, however, has been relatively expensive and is noteconomically feasible for relatively small contractors. Moreover,adjustments of the equipment to provide for variations in door width,door thickness, and door height have been relatively complex andtime-consuming It is a principal object of the present invention,therefore, to provide a new and improved automatic routing and drillingmachine for forming hinge iplate receptacles, lockset receptacles, and astriker plate receptacle in a door and a pair of door jambs, togetherconstituting a door assembly, all in a single operation.

A particular object of the invention is to provide a new and improvedautomatic routing and drilling machine for the fabrication of doorassemblies that can be quickly and conveniently adjusted to accommodatea wide Variety of standard door widths, lengths, and thicknesses.Further, it is an object of the invention to provide equal flexibilityin operation of the automatic drilling and routing machine for doorsthat are to be hung for left-hand or right-hand opening.

Another principal object of the invention is to provide a new andimproved method for processing door assemblies in which the three basicmembers of the door assembly are all held in fixed position relative toeach other during the complete drilling and routing operation. Thealignment of the door assembly components provided by the method of theinvention, and utilized in the machine of the invention, affords aconvenient work arrangement with no drills or routers located above thework to interfere with initial positioning of those components.

Another object of the invention is to aliord an improved method, and anautomatic routing and drilling machine, for the fabrication of doorassemblies, having complete flexibility with respect to variations indoor dimensions and in the direction olf hanging of the door withminimum adjustment in the routing mechanism employed to rout out thehinge plate receptacles in the door and in the hinge jamb.

Another object of the invention is to provide an automatic drilling androuting machine for sin gle-operation processing of door assemblies inwhich adjustments of the lockset drilling mechanism are limited to thosenecessary for variations in door width and thickness. That is, themachine requires no adjustment with respect to the lockset drillingapparatus as a result ofchanges in door height or changes in the sidefrom which the door is to be hung.

A particular object of the invention is to afford a complete automaticrouting and drilling machine for singleoperation processing of a doorassembly that inherently provides precise alignment of the lockset boltreceptacle in the door and of the striker plate receptacle in the jamb.

An important object of the invention is to afford a new and improvedautomatic drilling and routing machine for sin gle-operation processingof door assemblies that is simple and inexpensive yet provides arelatively high output.

Other and further objects of the present invention will be apparent fromthe following description and claims and are illustrated in theaccompanying drawings which, by way of illustration, show a preferredembodiment of the machine of the present invention and illustrate theprinciples of both the method and the machine, illustrating what is nowconsidered to be the best mode contemplated for applying theseprinciples. Other embodiments of the invention embodying the same orequivalent principles may be made as desired by those skilled in the artwithout departing from the present invention.

In the drawings:

FIG. 1 is a perspective view of a right-hand door assembly of the kindprocessed by the automatic drilling and routing machine of the presentinvention;

FIG. 2 is a perspective view illustrating the relative positions of thetwo door jambs and the door of a righthand door assembly duringprocessing ,in the automatic drilling and routing machine of theinvention;

FIG. 3 is a sectional view of the door assembly components as positionedduring processing taken approximately along line 3-3 in FIG. 2;

FIG. 4 is a sectional view of a completed door assembly, like that ofFIG. 1, illustrating the assembling of the components aftervfabrication;

FIG. 5 is a perspective view illustrating the components of a left-handdoor assembly positioned for processing;

FIG. 6 is a perspective view of an automatic routing and drillingmachine constructed in accordance with a preferred embodiment of thepresent invention;

FIG. 7 is an elevation view, on an enlarged scale, partly incross-section, of the left-hand portion of the routing head of theautomatic drilling and routing machine of FIG. 6;

FIG. 8 is a detail sectional view of a clamp mechanism, takenapproximately along line 8-3 in FIG. 7;

FIG. 9 is a detail sectional elevation view showing a portion of therouter operating mechanism for the routing head, taken approximatelyalong line 9-9 in FIG. 6;

FIG. 10 is a detail sectional elevation view taken approximately alongline 1til0 in FIG. 7;

FIG. 11 is a detail sectional elevation view taken approximately alongline 11-11 in FIG. 9;

FIG. 12 is a detail sectional elevation view taken approximately alongline l212 in FIG. 9;

FIG. 13 is a transverse sectional elevation view of the lockset drillinghead of the machine taken approximately as indicated by line 1313 inFIG. 6;

FIG. 14 is a partially cut-away side elevation view of the locksetdrilling head of the machine;

FIG. 15 is a longitudinal sectional view of the drilling head showingthe drill mechanisms; and

FIG. 16 is a detail circuit diagram of the electrical control system forthe machine.

FIG. 1 illustrates a door assembly 20 that is typical of the type ofdoor assemblies processed by the method and apparatus of the presentinvention. Door assembly 20 comprises two vertical frame members orjambs 21 and 22 and a transverse upper horizontal frame member 23. Adoor 24 is included in the door assembly and is hung upon the left-handjamb 21. Door assembly 20 is of the kind conventionally referred to as aright-hand door. That is, looking toward the door from the side of theframe 21-23 on which the door is hung, as in FIG. 1, the door is hingedon the left-hand jamb 21 and when closed locks with the right-hand jam'b22. For convenience, jambs 21 and 22 are sometimes referred tohereinafter as the hinge jamb and the lock jamb respectively.

When assembled, as shown in FIG. 1, door assembly 20 is provided withthree hinges 25, 26 and 27 by which door 24 is hung on hinge jamb 21. Alockset 28 is mounted in door 24 and includes the usual bolt 29projecting outwardly of the free vertical edge 31 of the door. Bolt 29is aligned with and engageable in an appropriate receptacle in the lockjamb 22, this receptacle being provided with an appropriate strike plate32.

FIG. 2 illustrates the manner in which the principal components of doorassembly 20, comprising jambs 21 and 22 and door 24, are aligned witheach other for drilling and routing in accordance with the presentinvention. As shown in FIG. 2, door 24 is supported in a given fixedplane; it should be emphasized that members 21, 22 and 24 remain in theposition shown in FIG. 2 throughout the drilling and routing operationsdescribed hereinafter. The hinge jamb 21 is mounted in flush alignmentwith one longitudinal edge 33 of door 24, this being the edge of thedoor that is to receive the hinges 27. The alignment is such that theedge 34 that is to be the lower edge of the door 24- is disposed a veryshort distance inwardly from the lower edge 35 of hinge jamb 21. Theupper edge 36 of the door is located immediately adjacent a rabbet orslot 37 in the hinge jam-b 21 that later receives the upper frame member23 of the door assembly (FIG. 1). As shown in FIG. 2, during processingthe hinge jamb 21 is aligned with door 24- but is disposed in a planenormal to the plane of the door so that the surface 38 of jamb 21 thatis to receive the hinges for the door is flush with the edge 33 of thedoor on which the hinges are mounted.

The lock jamb 22 is supported immediately above the hinge jamb 21 and inparallel alignment therewith. The rabbet or slot 39 in jamb 22 thatsubsequently receives the upper frame member 23 is directly aligned withthe corresponding slot 37 in jam'b 21.

With the door assembly components 21-23 mounted in the position shown inFIG. 2, a series of routing and drilling operations are performedthereon without movement of the door assembly components. Routers areutilized to out three hinge plate depressions or receptacles 41, 42 and43 in the longitudinal edge 33 of door 24. At the same time, threecorresponding hinge plate receptacles 51, 52 and 53 are formed in thehinge jamb 21 and more specifically in the surface 38 thereof that isaligned with the hinge edge 33 of door 24. The two mating hinge platereceptacles 41 and 51 are routed out in a single routing operation andthis is true of the remaining pairs of hinge plate receptacles.

Near the edge 31 of door 24, an aperture 55 is drilled through the doorto receive the cylinder for the lockset 28 (FIG. 1). As indicated inFIG. 2, the aperture 55 for the lockset cylinder is displaced by adistance D from the centerline of door 24, the centerline beingindicated at 56. The reason for the displacement D is that it istraditional to locate the door handle somewhat below the verticalmidpoint of the door.

Two additional drilling operations are performed on the components ofthe door assembly while aligned in the positions indicated in FIG. 2. Alockset bolt receptacle 57 is drilled in the edge 31 of door 24 toreceive the bolt for the lockset. The bolt receptacle 57 communicatesdirectly with the cylinder aperture to permit mechanical interconnectionof the bolt and cylinder port-ions of the lockset. In addition, a strikeaperture or receptacle 58 is drilled in the lock jamb 22 at the upperedge thereof. It should be noted that the axis of strike aperture 53,which affords a receptatcle for the projecting portion of the locksetbolt and for the striker plate, the axis of cylinder aperture 55, andthe axis of bolt aperture 57 all lie in a common plane identified by theintersecting phantom lines 61 and 62. The sectional view of FIG. 3 istaken approximately along this plane and shows the aligned relation ofthe several receptacles to be fitted with the lockset.

A comparison of FIGS. 3 and 4 shows the convenience and accuracy withwhich the jambs 21 and 22 and the door 24 may be assembled. As showntherein, the lock jamb 22 is aligned with the edge 31 of the door sothat the bolt 29 of lockset 28 projects into the bolt extensionreceptacle 58. The hinge jamb 21, on the other hand, is rotated throughan angle of 180 so that the hinges can be mounted in the matingreceptacles, such as receptacles 42 and 52, to hang door 24 on framemember 21.

FIG. 5 illustrates the alternate alignment that is employed forfabrication of a left-hand door assembly. As before, the door 24A issupported in a given plane and the hinge jamb 21A is aligned with thehinge edge 33A of the door. In this instance, however, the rabbeted endof jamb 21A that is to receive the upper horizontal element of the doorframe is located at the righthand end of the door as illustrated in FIG.5 instead of at the lefthand end. As before, the lock jamb 22A isdirectly aligned with the hinge jamb 21A with the rab beted portions ofthe two frame members aligned with each other. The two frame members areagain located in a plane normal to the plane of the door. As before, thebolt and cylinder apertures for the lockset are displaced by a distanceD from the centerline 55A of the door. In this instance, the left-handedge 34A is the bottom of the door and the displacement D is fromcenterline 56A toward edge 34A. In all other respects, the alignmentemployed for a lefthand door, as illustrated in MG. 5, is essentiallyidentical with that for a right-hand door as described above inconnection with FIG. 2.

FIG. 6 illustrates an automatic routing and drilling machine 6%) inwhich the routing and drilling techniques and the positioning of thedoor assembly components described hereinabove in connection with FIGS.1 through 5 are directly utilized. Thes machine 60 is of T-shapedconfiguration, the cross-bar of the T comprising a routing headgenerally designated by numeral 61. Routing head 61 includes means forclamping the door jam-bs 21 and 22 in working position and means forperforming the required hinge receptacle routing operation thereon. Thissame portion of the machine also includes the drill for forming strikereceptacle in lock jamb 22. The leg of the T terminates in a locksetdrilling head 62. Routing head 61 and drill head 62 are mounted upon asuitable rigid frame supported upon the legs 63.

The apparatus employed to support the hinge edge of hand edge as seen inFIG. 6, engages a pin 66 that is rigidly but removably mounted in shelfThe lower edge of door which is the lefthand edge as seen in FIG. 6, isengaged by a further pin 67 that projects upwardly from. shelf 64.

Pin 67 is not rigidly mounted in shelf 64; rather, a resilient mountingarrangement is employed that permits limited movement of the pinlongitudinally of the shelf. This mounting arrangement is bestillustrated in FIGS. 7 and 8. As shown therein, pin 67 is mounted in anaperture in a slide block 69 disposed within the interior of shelf 64.The upper end of pin 67 projects outwardly through an elongated slot 71in the upper side of the shelf. Slide block as is connected to a spring72 that pulls the slide blocl; toward the right as seen in FIGS. 6, 7and 8.

At the time an operator positions a door 24 in machine on, that portionof locks-ct drilling head 62 which engages the door is displaced to aposition clear of the door location in the machine, as is described morefully hereinafte With the lockset drilling head thus clear of the doorlocation, door 24 is moved into position from the right-hand side of themachine, as seen in MG. 6, with the side of the door adjacent the hingeedge resting upon shelf 64 but with the door held above pin on. Edge 34-of the door is brought into engagement with pin 67 and the operatorpushes longitudinally against the door until pin 67 is deflected to theleft through a distance sufficient to clear the upper edge 36 of thedoor over pin 66. The door is then dropped into position on shelf 64,the spring bias against pin 67 pulling the door back firmly against pin66. In this manner the door is accurately positioned in the machine andis ready for processing, once the clamp devices described hereinafter inconnection with mechanisms 6t and 62 are brought to bear thereon.

The relative positions used for pins 66 and 67 are dependent upon thedesired length of the door. For example, the pins may be positioned asshown for processing a standard six foot eight inch door assembly thatcomprises a right-hand door. If a taller door is required, as forexample a conventional seven foot door, then the fixed pin 66 may bemoved to an alternate receptacle to achieve the desired accuratepositioning of the door in the machine. One such alternate pinreceptacle 74 is shown in FIG. 6; additional receptacles for furtherstandardized door heights may be provided if required. The slide pin 67does not require a change to compensate for variations in door height.

When the machine 60 is to be employed in processing a lefehand door, thepins as and 67 are reversed with respect to their functions. Referringto FIGS. 7 and 8, it is seen that the left-hand end of the channel shelf64 is provided with two pin receptacles 75 and 76. If a lefthand door ofstandard six foot eight inch height is to be processed, pin 67 isremoved from slide block 69 and placed in receptacle 75 where it servesas the fixed base pin for locating a door in the machine. if a sevenfoot door is to be processed, pin 67 is placed in receptacle 7d. Theadjustment of the machine for processing of a lefthand door, as regardspositioning of the door in the machine, is completed by removing pin asfrom its fixed position as shown in PEG. 6 and replacing this pin in aslide block (not shown), like slide blocl; 69, that is located in theright-hand end portion of shelf 64. The loading technique for placingthe door in the machine is the same as described above except that theoperator works from the left-hand side of the machine instead of theright-hand side.

Near the right-hand end of routing head 61, as seen in FIG. 6, a rigidbut removable jamb stop 77 is mounted upon and projects outwardly of thefront face of the router head. With the door 2.4 in place, as describedabove, the machine operator slides the hinge jamb 211 across the topsurface of the door but clear of the fixed jamb stop 77 and intoengagement with a spring biased d sliding jamb stop 73 that is locatedat the opposite end or" router head till from stop 77.

As shown in FIGS. 7 and 8, the sliding jamb stop '73 is mounted upon ashaft 79 that extends through an elongated slot 89 in the face plate andinto a soclret or receptacle in a slide block hi that is mounted uponthe inner surface of the face plate. Slide block 81 is supported upon apair of studs 82 that are atfixed to the router head face plate 65.Studs 32 engage in elongated slots 83 in the slide block so that theslide block is permitted a substantial degrees of movement of the leftand to the right as seen in FTC-S. 6 and 8. A spring 84 is connected toslide block 81 and biases the slide block to the right. It is thus seenthat s ring 34 is effective to bias the slidable jamb stop 78 toward thefixed jamb stop 77 at the other end of the router head.

The machine operator pushes the jamb 21 against slidable jamb stop 7%}and moves the slidaole jam stop to the left through a distancesufiicient to enable him to engage the fixed jamb stop 77 in the slot 37that ultimately receives the upper frame member 23 of the door assembly(see FIGS. 1 and 2). The flared end portion hr: of the movable jamb stop78 (FIGS. 68) permits initial insertion of jamb 21 into the machine atan angle so that the foregoing operation can be carried out quickly andconveniently. An inwardly projecting pin 37 on jamb stop 73 engages theedge of jamb 21 and holds the jamb firmly in aligned longitudinalposition.

The same technique is followed by the operator in mounting the lock jamb22 in machine 60. That is, the operator slides lock jamb 22 intoposition on top of hinge jamb 22 and then moves the lock jamb toward theface place 65 to bring the fixed jamb stop 77 into locking engagement inthe rabbet or slot in the jamb member. Lock jamb 22 is engaged by aninwardly projecting pin 88 on the slidable jamb stop 78 and thus is heldfirmly in position. A wear plate 87 may be provided upon the face plate65 of router head 61, behind the jambs, to protect the face plateagainst abrasion from movement of the jambs into and out of the machine.

For a taller dor, it is necessary to adjust the position of the fixedjamb stop 77. This is accomplished simply by removing the fixed jambstop from face plate 65 (FIG. 6) and re-mounting the same at therequired position for the longer door. In the illustrated embodiment,face plate 65 is provided with a pair of tapped openings 91 or othersiutable mounting elements to permit quick and convenient re-mounting ofthe fixed jamb stop 77 in position for a taller standard door.

For processing of a left-hand door, the conversion of the jamb-mountingapparatus is as simple as that for the door-positioning apparatus. Theslidable jamb stop 73 is removed from slide block 31 (FIG. 8) by pullingthe jamb stop shaft 79 outwardly of the slide block through slot 8d andis then repositioned in a similar slide block (not shown) located nearthe right-hand end of the router head. To mount the jarnbs on themachine, the same technique is followed as described above for aright-hand door except that the operator works from the left-hand sideof the machine and engages the rabbetted or slotted portions of thejambs with a rigid jamb stop 93 located at the left-hand side of themachine. The mounting position for the jambs is illustrated by the dashoutline 22C in FIG. 8. For complete flexibility, with respect to doorheight, one or more alternate mounting positions for the rigid jamb stop93 may be provided at the lefthand side of the machine as shown in M05.7 and 8.

Machine 6d, as thus far described, positions the door 24 and jambs 2tand 22 in longitudinal alignment, with the two jambs disposed in a planeperpendicular to the plane of the door .24 and in alignment with thehinge edge of the door. For processing of the jambs and of the hingeedge of the door, however, it is essential that the workpieces beprevented from moving vertically. It

is also necessary to restrain the jambs against horizontal movementoutwardly of face plate 65. Two interconnected clamping and restrainingdevices 101 and 1&2 are employed for this purpose (FIG. 6). Inasmuch asthe two clamping devices 101 and 162 are essentially identical inconstruction, only the device 101 is shown in detail in the drawings.

As illustrated in FIG. 6, a clamping rack 103 extends across the face ofrouter head 61 in alignment with the two jambs 21 and 22. Rack 1113comprises a pair of elongated bars or pressure members 104 and 1115interconnected at spaced points by three cross bars 106, 1117 and 108. Acentral bar 109 is incorporated in the rack 103 and extends parallel topressure bars 1114 and 105'. The long bars 1114, 105 and 1119 are allwelded or otherwise rigidly secured to cross bars 106, 107 and 1118 toafford a rigid rack assembly.

The clamping and retaining mechanism 101 comprises a verticallyextending arm member 111, the lower end of which is rigidly afiixed asby welding to the central bar 1119 in the rack assembly 103. The upperend of arm 111 is affixed to a lever 112 that projects through anopening 113 in the face plate of routing head 61. Lever 112 is pivotallymounted on a suitable shaft or pivot pin 114 as shown in FIGS. 7, 9 and10. Shaft 114 is mounted in a bracket 115 extending downwardly from thetop plate 116 of routing head 61.

Lever 112 includes a downwardly extending lug 117 that is pivotallyconnected by a pin 118 to a link 119 (FIGS. 9 and Link 119, in turn, ispivotally connected by a suitable pin 121 to a crank 122 affixed to oneend of an actuator shaft 123. Shaft 123 is rotatably driven by anelectrically operated actuator mechanism 124 that is described morefully hereinafter. For the present, it is sufficient to note thatactuator 124 comprises a small electric motor that rotates shaft 123through an angle of 180 each time the motor is energized. Actuator 124is provided with a second shaft 125 that is a continuation of shaft 123and that is used to drive the other clamping and retaining device 1112(FIG. 6).

In FIGS. 6, 7, 9 and 10, the clamping apparatus comprising devices 1111and 1112 is shown in clamping position. In this position, the upper bar1115 of rack 1113 presses against lock jamb 22 and holds the jamb firmlyagainst the wear plate 89 on the front face 65 of routing head 61.Similarly, the lower bar 1114 of the pressure rack presses against hingejamb 21 and maintains the hinge jamb in firm engagement with the wearplate. A pressure clog 127 that is mounted upon arm 111 of clampingdevice 1111 engages the top edge of lock jamb 22 and presses the twojamb members and the door 24 downwardly into firm engagement with shelf64. A simi lar pressure dog 128 in device 1112 (FIG. 6) also pressesdownwardly, pushing the two jamb members and the door into firmengagement with shelf 64-. Thus, with the clamping system comprisingdevices 1111 and 1122 and rack 1113 in the position shown in thedrawings, the two jamb members are firmly held against lateral movementaway from wear plate 83 on the face of the routing head 61. The jambmembers and door 24 are also held against vertical movement, beingpressed downwardly into firm engagement with shelf 64.

To remove the door and the jambs from the routing head at the end oftheir processing, actuator 124 is energized and rotates shafts 123 and125 through an angle of 180. As a consequence, and through the linkageprovided by crank 122 and link 119, lever 112 is rotated in a clockwisedirection as seen in FIG. 10. This pivots the left-hand end of lever 112upwardly and away from the jambs 21 and 22. A similar operation takesplace simultaneously at the other clamping device 102 (FIG. 6), which isactuated simultaneously through the shaft 125 (FIG. 9). The pivotalmovement of lever 112 releases dog 127 from engagement with the top edgeof jamb 22 and the corresponding movement in the other clamping device102 releases dog 128 from engagement with the &

lock jamb. Simultaneously, rack 103 is lifted upwardly and outwardlywith respect to the two jamb members so that the pressure bars 104 andare disengaged from jambs 21 and 22 respectively. It is thus seen thatthe energization of actuator 124 releases both of the clamp ing devices161 and 102 and frees the two jamb members and the door for removal fromthe machine.

When the processed door and jambs have been removed from the machine anda new door and jambs are placed therein as described above, actuator 124is energized, at

the beginning of a processing cycle, and again rotates shafts 123 andthrough one-half revolution. The operating linkages of the two clampingdevices 101 and 102 are thus actuated to return the clamping apparatusto the position shown in drawings, with the rack 103 pressing the twojambs against wear plate 89 and with the dogs 127 and 128 pushing thejambs and the door downwardly into firm engagement with shelf 64.

The principal function performed by routing head 61 is the routing ofthe three sets of hinge receptacles in the edge of door 24- and in thesurface of hinge jamb 21. The routing mechanism is best illustrated inFIGS. 9 and 11. It should be noted that FIG. 9 shows only slightly morethan one-half of the routing head and that the other half is anessential duplicate thereof; the same is true with respect to FIGS. 7and 8.

The routing mechanism of routing head 61, as shown in FIGS. 9 and 11,comprises a first elongated frame 131 that extends the full length ofthe routing head. This first frame 131 comprises a pair of verticalframe mem bers 132; only the one frame member 132 is illustrated in FIG.9, the corresponding vertical frame member being located at the oppositeend of routing head 61. These two vertical frame members are joined neartheir lower ends by a transverse frame member 133 that is rigidlyaflixed to each of the two vertical frame members. The upper end of eachvertical frame member 132, as illustrated in FIG. 9, is pivotallymounted upon an elongated guide shaft 134 suspend-ed from the top plate116 of routing head 61 by suitable means such as a pair of brackets 135.A similar mounting arrangement, including a similar guide shaft, is usedfor the other vertical frame member (not shown) at the opposite end ofthe routing head. it is thus seen that the complete frame 131 can pivotabout the axis of the guide shafts 134 toward and away from the faceplate 65 of the routing head 61.

As shown in FIGS. 9 and 11, the lower end of vertical frame member 132is pivotally connected to one end of a link 137. The other end of link137 is pivotally connected to a crank 138 that is fixedly mounted on theend of a drive shaft 139. Shaft 1.39 is driven by an electrical actuator141, the actuator 141 including a second shaft 142 that extends acrossthe routing head to the other vertical frame member and is connectedthereto by a linkage (not shown) similar to that comprising crank 138and link 137.

An elongated guide rod 143 is fixedly mounted upon the transverse framemember 133 of frame 131 and extends between the vertical frame member132 and a bracket 144 that is mounted upon frame member 131. Acorresponding guide rod, not shown, is provided at the opposite end ofthe routing head, extending parallel to the other end portion oftransverse frame member 133. Guide rod 14-3, together with shaft 134-,is employed to support and to guide horizontal movements of a secondframe 146 that is incorporated in the routing mechanism of the machine.

Frame 1 16 includes a pair of parallel elongated transverse framemembers 147 and 149 that extend throughout substantially the full lengthof routing head 61. One end of frame member 147 is rigidly affixed to avertical frame member 1 as shown in FIG. 9. The opposite end of framemember 147 is rigidly secured to a similar vertical frame member (notshown) at the opposite end of the ii routing head. Vertical frame member148 is slidably engaged on each of the twoguide rods 134 and 143, and asimilar arrangement is used at the opposite ends of the routing head.Thus, the complete frame 146 is mounted for sliding movement in adirection indicated by the arrows X in FIG. 9. The other transverseframe member 149 extends parallel to frame member 1 17 and is affixed tothe vertical frame members, such as frame member 148, at the medialportions thereof. Additional vertical braces 159 may be provided inframe 146.

An electrically driven actuator 151 is provided for frame 146. The driveshaft 152 of actuator 151 carries a crank 153 that is pivotallyconnected to a link 154-. Link 154 in turn is pivotally connected to oneend of an elongated lever 155. A pin 156 mounted on the other end oflever 155 fits into a socket in the lower transverse member 147 of thesecond frame 146, pivotally connecting lever 155 to frame 146. Themechanism is shown with the linkage 153-155 at the mid-point of anoperating cycle because illustration of the apparatus at either end ofits operating cycle would cause lever 155 to obscure part of theconnections for the transverse frame member 147 (FIG. 9). It should beunderstood that completion of an operating cycle for actuator 151 wouldrotate shaft 152 through an angle of 90 from its illustrated positionand that a complete half-revolution cycle of the actuator moves frame146 through a predetermined distance horizontally as indicated by thearrows X.

There is a further router positioning frame 161 in routing head 61 thatis connected to frames 131 and 146, these three frames conjointlyoperating to define an operating cycle for the routing devices asdescribed hereinafter. This third frame 161 comprises two elongatedframe members 162 and 163 that extend substantially the full length ofrouting head 161 and that are joined to each other by a series of threerouter mounting plates. Two of these router mounting plates 164 and 165are shown in FIG. 9; it should be understood that there is a third suchmounting plate located in the right-hand portion of the routing head ina position similar to that illustrated for plate 164.

The third positioning frame 161 is driven by an electrically poweredactuator 168 comprising a motor having two output shafts 169 and 171.Actuator 168 is mounted upon the upper transverse frame member 149 offrame 146. The end of shaft 169 opposite the actuator projects throughand is supported by a bearing 172, the bearing mounted upon frame member149. The end of the shaft 169 carries a crank 173 that is .pivotallyconnected to one end of a link 174. The opposite end of link 174 ispivotally connected to the end of the upper transverse frame member 163of frame 161. A similar linkage (not shown) is utilized at the oppositeend of the machine to connect shaft 171 to frame member 163.

As illustrated in FIGS. 9 and 11, the actuating mecha nism for frame 161is at one end of its operating cycle. A first complete operating cyclefor actuator 168 rotates shafts 169 and 171 through an angle of 180 andmoves the complete frame 161 upwardly through a predetermined distance.In a second operating cycle, actuator 168 again rotates the actuatorshafts through 180 and moves frame 161 downwardly through the samedistance. It is thus seen that actuator 168 drives frame 161 through apredetermined vertical distance, as indicated by the arrows Y, in eachcycle of its operation.

There are six router openings located at spaced intervals across theface plate 65 of router head 61. In FIG. 9, three such openings 181, 182and 163 are shown. It should be understood that there are threeadditional router openings (not shown) located to the left of thatportion of the routing head that is illustrated in FIG. 9. Threeindividual routers are incorporated in the routing head 61, two of theserouters 184 and 185 being shown in FIG. 9. The third router for themachine is located to the left of router 135 as shown in FIG. 9 and isdisltd placed therefrom by a distance equal to the spacing betweenrouters 184 and 185.

To rout the three sets of hinge cavities or receptacles in door 2-1 andin hinge jamb 21 as described hereinabove in connection with FIG. 2, itis necessary to move the three routers such as routers 184 and in threedirect-ions. Initially, the routers are advanced from a retractedposition displaced from the workpieces to an engaged position in whicheach router cuts into the Wood workpieces as shown in FIG. 11. Thisadvancing movement toward the workpieces is accomplished by pivotalmovement of frame 131 effected by actuator 1 11.

Once the three routers are advanced to cutting position by actuator 141,they are moved through. a rectangular path, in a vertical plane, to routout the desired substantially rectangular hinge plate cavities. Theinitial vertical movement is accomplished by energizing actuator 16 8 tomove the routers upwardly, this movement being effected by upwardmovement of frame 161 as indicated by the arrows Y. When the initialupward movement has been completed, actuator 151 is energized to movethe routers horizontally through a given distance as indicated by thearrows X. Actuator 168 is then energized to drive the actuators, throughframe 161, back downwardly to their original level. Actuator 151 is thenenergized to move frame 146 back in a horizontal direction to theirinitial position. Finally, actuator 141 is energized. to rotate shaft142 through a further 180 cycle and retract the complete assembly ofthree routers by pivotal movement of frame 131.

The router frame mechanism, as illustrated in FIG. 9, is set up for astandard six foot eight inch left-hand door. To compensate for thedifferent length of a seven foot door, the connection between lever 155and frame member 1147 may be changed by removing pin 156 from itsillustrated connection to the frame member and inserting the pin in afurther socket 188. This compensation is not absolutely essential ifsome assymmetry' is permissible in the hanging of the seven foot door,but is relatively easy to accomplish if complete symmetry is desirable.

When the machine is to be employed for processing of right-hand doorassemblies, it is necessary to re-position the routers. The need forthis change is apparent when it is considered that the door and jambmembers are mounted differently in the machine for left and right-handdoors (and in View of the off-center alignment of the locksetreceptacles in the door, all as described above. To condition themachine for processing of a six foot eight inch right-hand door, pin 156is connected into a different socket 189 in frame member 14-7. Thischange shifts the complete frame 166 a substantial distance to the leftas seen in FIG. 9 and aligns router 184 with opening 182 in face plate65 instead of with opening 181 as shown. A similar re-alignment takesplace with respect to the remaining two routers of the machine. Again,compensation for a seven foot door may be accomplished by changing theconnection of the pin 156 to an additional socket 191 in frame member 147. The router openings such as openings 181-183 are made Wide enough toavoid interference with the routers whether operating on six foot eightinch doors or seven foot doors.

The routing and drilling head 61 also includes the mechanism fordrilling the strike receptacle: $8 (FIGS. 2 and 3) in lock jamb 22. Thedrilling mechanism employed for this purpose is best shown in FIGS. 9and 12. As shown therein, a bracket 195 is mountedat the center of faceplate 65 in the upper portion of the face plate. Bracket 195' is securedto face plate 65 by a clamp screw 196 that extends through an elongatednarrow slot 197 in the face plate (see FIGS. 7 and 12) and is threadedinto the bracket. The lower end of bracket i195 is provided with anelongated slot 198 that receives a pin 199. Pin 199 is afiixed to andprojects inwardly of face plate 65 and is utilized to guide bracket 195and to maintain the bracket in fixed vertical alignment on the faceplate.

Bracket 195 carries a pair of horizontal shafts 201 that areperpendicular to the plane of face plate 65. A yoke 2112 is slidablymounted upon the two shafts 201 and this yoke supports an electricallydriven drill 203. Yoke 201 is pivotally connected to one end of a link204; the other end of the link 204 is pivotally connected to a crank 205carried by the shaft of an electrically driven actuator 206. Actuator206, when energized, advances drill 203 to bring the cutting member 207into engagement with the upper edge to lock jarnb 22 to drill the strikereceptacle in the jamb. The cutting element 207 of drill 203 projectsthrough an appropriate opening 208 in the face plate 65 of routing head61.

In some instances, it may be desirable to change the width of the jambsto suit particular job requirements or for other reasons. Moreover, itis desirable to align drill 2113 quite accurately with respect to theupper edge of jamb 22 to assure precise location of the striker platereceptacle in the jamb. To this end, a gauge member 2111 is incorporatedin the mounting arrangement for drill 203. Gauge 210 is affixed to andextends downwardly from a collar 212 through which clamp screw 196extends. When jamb members of a new standardized width, or of anindeterminate width, are mounted in the machine clamp screw 196 isretracted a distance sufficient to release bracket 155 for verticalmovement from its normal clamped engagement with face plate 65. With theclamp screw 196 thus released, the weight of the bracket and drill movesthe drill assembly downwardly until gauge member 210 engages the topedge of jamb 22 as shown in FIG. 12. The clamp screw 196 is thentightened and the drill is accurately positioned for forming the desiredstrike receptacle.

The frame of the automatic routing and drilling machine 60 (FIG. 6)includes a pair of fixed rails 211 and 212 that extend parallel to eachother along the leg of the T-shaped machine. Rails 211 and 212constitute support rails for the lockset drilling head 62 of themachine, which is illustrated in detail in FIGS. 13-15.

A base member 213 (FIG. 14) is suspended from rails 211 and 212. At theouter or left-hand end of base 213 there are a pair of vertical hangermembers 214 that project upwardly from the base member. Each of thesehanger members 214 is provided with a socket portion 215 that receivesan inwardly projecting ledge portion on the respective one of the rails211 and 212 with which the hanger member is aligned (see FIGS. 13 and14). In addition, the front or right-hand end of base 213 includes anadditional pair of vertical hanger members 216 each provided with asocket portion 217 that encompasses the associated rail and providesfurther support for the base.

As discussed hereinabove, machine 61) accommodates a wide variety ofdoors of varying width. To adjust the lockset drill head 62 to aparticular door width, the position of base 213 is changed by slidingthe base along the parallel support rails 211 and 212. Thus, for aparticular door width, the base member is moved longitudinally of therails to the desired position and a retainer rod 218 is inserted throughthe appropriate one of a series of holes 219 in rail 212 and through acomplementary opening in the vertical hanger member 216 at the front ofbase 213. Rod 218 extends completely across base 213 and through thevertical hanger member 216 on the opposite side of the lockset drillhead, as shown in FIG. 13, and out through an aligned aperture in rail211. This suspension arrangement locates base member 213 in fixedlongitudinal position on the rails 211 and 212.

A main drill carriage 221 is also mounted upon rails 211 and 212 forsliding movement along the rails. Carriage 221 includes a pair oftransverse support bars 222 and 223 that project outwardly of thecarriage, on the sides thereof, each of these support bars beingprovided with appropriate slots for engaging and receiving the 12 upperportions of rails 211 and 212. Preferably, stipport bars 222 and 223have slotted ends engaging both the upper and lower faces of the lipportions of the rails to hold the carriage 221 down on the rails.

Main drill carriage 221, the internal construction of which is describedmore fully hereinafter, supports a pressure gauge member 224. Variationsin the geometry of the lockset may require changes in longitudinalalignment of the pressure gauge member 224 relative to carriage 221, asdescribed more fully hereinafter. Provision for such longitudinaladjustment is incorporated in drill head 62 by connecting member 224 tocarriage 221 by means of an elongated retaining rod 225 that extendsacross the outer end of gauge member 224 and through mating apertures inthe gauge member and in the carriage. Pressure gauge member 224 isprovided with a series of apertures 226, making it possible to effectthe required longitudinal adjustment of members 221 and 224.

An electrically driven actuator 227 is mounted upon the bottom of basemember 213. The output shaft 228 of actuator 227 carries a crank 229that is connected to one end of a link 231, as best illustrated in FIG.14. The other end of link 231 is pivotally connected to an additionallink 232 near the righthand end of link 232 as seen in FIG. 14.

The rear or left-hand end of link 232 is pivotally connected to theupper end of the hanger 214 that is an integral part of base member 213.The right-hand end of link 232 is pivotally connected to a crank-shapedarm 234 that is a part of a pressure yoke 235. The crank arm 234 ispivotally connected to pressure gauge member 224 by a pin 236. Theforward or right-hand end of the crank arm is connected to a transversebar member 237 that extends across the lockset drill head 62 as shown inFIG. 13 and is connected to a corresponding crank arm 238 on theopposite side of the machine. The other crank arm 238 of yoke 235 isconnected to a similar linkage on the opposite side of the machine,including a horizontal link 241 and a vertical link 242, the latterbeing connected back to a crank 243 on the end of actuator shaft 223opposite crank 229 (see P16. 12). The outer ends of the two crank arms235 and 238 carry a pair of pressure rollers 246 and 248, respectively,that engage the surface of door 24 to clamp the door in place asdescribed more fully hereinafter.

The left-hand portion of main drill carriage 221 includes a pair ofelongated horizontally extending support rods 251 and 252. Rod 251 is afixed support member, extending from a forward wall 253 of carriage 221to the rear wall 254 thereof. Rod 252 extends between the same twocarriage walls 253 and 254 but is brought out beyond wall 254 and isprovided with a handle 255 to permit rotation of the support rod.

Support rods 251 and 252 are utilized to support a bolt drill carriage256 within the main drill carriage 221. Thus, rod 251 extends throughthe front and rear walls of the bolt drill carriage 256 and supports theright-hand portion of the carriage, as viewed in FIG. 13, at a fixedvertical position. The left-hand portion of the bolt drill carriage 256is provided with a pair of rectangular openings, one such openings 257being illustrated in FIG. 13. These two openings are aligned withsupport rod 252. A pair of eccentrically mounted polygonal cam supportmembers 258 (shown as rectangular in configuration) are affixed tosupport rod 252 in alignment with the openings 257 to support theleft-hand side of bolt drill carriage 256. This mounting arrangementmakes it possible to make minor changes in the height of the drillemployed to form the bolt aperture in the door described more fullyhereinafter.

An electrically powered actuator 261 is mounted in the lower portion ofbolt drill carriage 256 (FIGS. l3 and 15), actuator 261 being providedwith an output shaft that carries a spur gear 262. Spur gear 262 isdisposed in meshing engagement with a rack 263 mounted upon id a yoke264. Yoke 264 is slidably mounted upon a pair of. elongatedlongitudinally extending support and guide rods 265 that extend from thefront to the rear of bolt drill carriage 256. Yoke 264 is the supportfor a conventional electrically powered drill 266; the operating shaft267 of the drill projects through openings in the front wall of the boltdrill carriage 256 and in the adjacent wall of the main carriage 2.21 inalignment with an opening 268 in the front or right-hand wall of gaugeand pressure member 224 as shown in FIG. 15.

At the front or right-hand end of the main drill carriage 221, as seenin FIGS. 14 and 15, there is a downwardly projecting enclosed frame 271.A pair of vertical guide rods 2 72, of which only one is illustrated inthe draw logs, are mounted within this portion of the main drillcarriage. A yoke 273 is slidably mounted on these vertical guide rods. Arack gear 274 is mounted upon yoke 273 and projects downwardly therefrominto meshing engagement with a spur gear 275. Spur gear 275 is affixedto the output shaft of an additional electrically powered actuator 276that is mounted within the vertical portion 271 of main drill carriage2Z1.

Yoke 2 73 supports a conventional electrically powered drill 277 that isutilized to drill out the cylinder opening for the lockset, in door 24-,as explained more fully hereinafter. The operating shaft and cuttinghead of drill 277 are aligned with a suitable opening 278 in the top ofthe enclosed frame 271.

The front or right-hand end of the main drill carriage 221, comprisingthe vertical section 2'71, also carries a wear plate 281. When door 24is mounted in the ma chine, the door may rest directly upon wear plate281 and upon shelf 64. As shown in FIG. 15, however, it may be desirableto insert shims 282 and 2% on wear plate 281 and shelf plate 64 toelevate door 24 slightly above the upper surfaces of the wear plate andthe shelf. Such shims may be utilized to compensate for variation indoor thickness; for example, in a given machine, doors intended forexterior use, and of a first given thickness, may be supported directlyupon the wear plate 2551 and upon the shelf 64, whereas somewhat thinnerstandardized doors for interior use may be mounted upon the shims 282and 233 as illustrated in FIG. 15.

FIGS. 14 and 15 illustrate lockset drill head 62 in an operatingposition achieved by the apparatus immediately following the drilling ofthe bolt aperture 57 and the cylinder aperture 55 in the door. At thispoint in the operating cycle of the machine, and with the drills 266 and277 in the position shown, actuator 22) may be energized to rotate itsshaft 228 through an angle of 180, pivoting cranks 229 and 243 from theposition illustrated in FIGS. 12 and 14-, in which the cranks projectdirectly upwardly, to an alternate operating position in which the twocranks extend directly down from the axis of the actuator shaft. Thispivotal movement of crank 22% pulls link 231 to the position generallyillustrated by the phantom line 231A (FIG. 14) and thus pivots link 232in a clockwise direction to the position generally illustrated by thephantom line 232A. This action pulls crank 234 to the left from theposition shown in FIG. 14 and also pivots the crank in acounterclockwise direction about its pivot pin 236 so that the generalposition of the crank is that shown by the phantom lines 234A. As aresult, pressure rollers 245 is pivoted upwardly and away from thesurface of door 24 to the position indicated by the phantom outline245A. This releases the edge portion of the door for vertical movement.At the same time that the yoke comprising crank 23 i is thus pivotedupwardly and away from the door, the pressure gauge member 224 moves tothe left away from the edge of the door, due to the connection affordedby the pin 236 between the yoke and the pressure gauge member.Accordingly, it is seen that the door is freed for movement horizontallyand vertically, enabling the machine operator to lift the door from themachine.

ozone When a new door is loaded in the machine, actuator 227 is againenergized to rotate its shaft 228 through rotating cranks 229 and 243back to the positions illustrated in FIGS. 13 and 14. This drives thelinkage 231i, 232 and the pressure yoke 235 back to the position shownin the drawings with the pressure rollers M5 and 248 pressing door 24downwardly against the wear plate member 281. in this manner, the dooris held firmly against vertical movement, in the area immediatelyadjacent the lockset drill head. At the same time, the connectionprovided by pin 236 between the pressure yoke 235 and the pressure gaugemember 224 moves the pressure gauge member back to the right and bringsthat member into engagement with the edge of the door as shown in FIGS.14 and 15.

The next stage in the operation can be the actuation of either thecylinder drill 277 or the bolt drill 266. Assuming bolt drill 266 is tobe operated first, then actuator 261 is first energized. The rack andpinion drive comprising spur gear 262 and rack 263 then drives yoke 2ndto the right along guide rods 265 (FIG. 15) to drill the bolt aperture57 in the door. When this drilling operation is completed, the directionof rotation of actuator 261 is reversed and the drill is retracted toits initial position as shown in FIG. 15.

The next operation is to energize the electrically driven cylinder drillactuator 277. Drill 277 is moved upwardly by the rack and gear drive274, 2'75 and drills the cylinder aperture 55 in the door. When thisdrilling operation is completed, continued operation of actuator 276,but with reverse rotation, is effected to retract drill 277 to itsoriginal position as shown. This completes the drilling of the door forthe lockset; the door can thereafter be released as described above andreplaced by another door.

Different locksets may require different lengths for the bolt receptacle57. Any changes required in this regard may be effected by withdrawingthe retaining rod 225 and adjusting the relative positions of the drillcarriage 221 and the pressure gauge member 2% by selection of therequired retaining rod opening 226 in the pressure gauge member. Becauseof the relatively large size of cylinder aperture 55 and the relativestandardization of bolt lengths, a series of three or four adjustablesettings for the pressure gauge member are adequate to permit operationof the machine for a wide variety of different locksets.

It is desirable to have the bolt aperture 57 accurately aligned with thecenter plane of door On the other hand, changes in door thickness,accommodated by use of the shims 282 and 2835, may change the alignmentof the bolt drill shaft 267 with respect to the center of the door whenthe door is mounted in the machine. This variation in alignment can beeffectively compensated by rotation of the support shaft 255 thatcarries the left-hand portion of. bolt drill carriage 256 (FIG. 12).Thus, the eccentric mounting of the support blocks or cams 258 on shaft252 makes it possible to effect small variations in the height of thedrill 2156 to afford precise alignment of that drill with the centerplane of the door.

Adjustment of lockset drill head for variations in door width is arelatively simple matter. To accommodate a door that is substantiallynarrower than the door 24 illustrated in FIG. 14, retaining rod 23.8 iswithdrawn and the complete drill head 62 is moved to the right alongrails 211 and 212 to the required position for the narrow door, and theretaining rod 218 is re-inserted through the appropriate aligned holes12.19 in the rails. The socket holes 219 can be marked for various doorwidths so that the machine operator is not required to estimate whichmounting hole should be used for a door of a given specific width.

FIG. 16 illustrates a preferred form of automatic control circuits foractuating and controlling the complete operations of the machine ed asdescribed hereinabove. That is, the circuit illustrated in FIG. 16 iseffective to control the actuation and operation of the electricallydriven drills 203, 256 and 277 and the routers 134 and 185 as well asthe third router of the machine.

The principal control elements of the machine, all of which are shown inFIG. 16, comprise the actuators 124, 141, 151, 158, 206, 227, 261 and276, all of which have been described hereinabove with respect to theirmechanical connections to the machine and their mechanical functions.Each of these actuators comprises a small electrically driven motorhaving appropriate field windings and a rotor for driving the actuatorshaft. However, there are variations in the actuator construction,depending upon the task to be performed by each actuator.

Thus, the lockset clamp actuator 227 illustrated in the upper right-handcorner of FIG. 16 comprises a small electric motor including a rotor 301having two field windings 302 and 333 that are connected to each other,the common terminal of windings 302 and 303 being returned to ground. Acapacitor 304 is connected across windings 302 and 303. The output shaft228 of actuator 227 carries a cam 305 that engages and actuates themovable contacts 306 and 307 of two single-pole double-throw switches300 and 308, respectively. As can be seen from FIG. 16, cam 395 engagesmovable contact 306 in a first operating position for the actuator,referred to hereinafter as the home position. Rotation of the shaftthrough 180 causes the cam to engage and actuate the second movablecontact 307 of the actuator.

The hinge clamp actuator 124 is similar in construction to actuator 227.Thus, the operating shaft 123 of this actuator drives a cam 309 thatactuates the movable contacts 311 and 312 of a pair of single-poledouble-throw switches 310 and 313, respectively. In its initial or homeposition, the actuator cam 309 engages movable contact 311. Rotation ofshaft 123 through an angle of 180 brings the cam into engagement withmovable contact 312.

The three coordinate actuators for moving the routers to rout out thehinge receptacles, actuators 141, 151 and 168, are of similarconstruction. Shaft 139 of actuator 141 is provided with a cam 314 thatnormally engages the movable contact 315 of a first single-poledoublethrow switch 317 but is engageable with the movable contact 316 ofa second single-pole double-throw switch 313 upon rotation of theactuator shaft through an angle of 186. Shaft 169 of router movementactuator 168 carries a cam 319. Cam 319 is engaged with the movablecontact 321 of a first single-pole double-throw switch 32d when theactuator is in its initial operating position as shown and is engageablewith the movable contact 322 of a similar switch 323 upon rotation ofthe actuator shaft through one-half revolution. The cam on shaft 152 ofrouter actuator 151 is designated by reference numeral 324 and isengaged with the movable contact 325 of a first single-pole double-throwswitch 327 when actuator 151 is in its home position. Cam 32 engages themovable contact 326 of a similar switch 322% upon rotation of shaft 152through an angle of 180.

The strike drill actuator 205 is similar to the actuators describedabove but somewhat simpler in construction. Thus, the shaft of thisactuator carries a cam 329 that normally engages first movable contact331 of a single-pole double-throw switch 330 to hold that contact inpredeter- :rnined position. Upon rotation of the output shaft of:actuator 206, cam 329 is released from contact 331 and permits thecontact to move to an alternate position, the contact 331 remaining inits alternate position until a full revolution of the actuator shaft iscompleted.

The bolt drill actuator 251 and the hinge drill actuator 276 are similarto each other but are somewhat different in construction from the otheractuators. Considering actuator 261, it is seen that this device is asmall electric motor including field windings 332 and 333 electricallyconnected to each other with the common terminal of the windingsgrounded. A capacitor 334 is connected across the two windings. Therotor 335 of the motor drives the spur gf flf 62 ,(see FIG. 15) thatmeshes with rack 263.

One end of rack 2&3 (FIG. 16) is engaged by a lever arm 338, lever 338being maintained in contact with the end of the rack by a spring 339.Arm 338 is mechanically connected to and controls the position of themovable contact 341 of a single-pole double-throw switch 340. Rack 263also controls a reversing switch 3-37 comprising a lever arm 342 that ismechanically linked to and controls the position of the movable contact343 of the switch. Switch 337 is a toggle-action device, movable contact343 changing its position only when lever 342 moves from one extremeposition to another. The fixed contacts of switch 337 are connected tothe field windings 332 and 333 of the actuator.

An essentially identical arrangement is used for hinge drill actuator276 and comprises the spur gear 275 mounted on the actuator shaft inmeshing engagement with rack 274. A pivotal lever 348 is maintained inengagement with one end of rack 274 by suitable biasing means such as aspring 49. Lever 348 controls the position of the movable contact 351 ofa single-pole double-throw switch 350. A toggle switch 347, comprising alever arm 352 controlling the operating position of a movable contact353, is used at the other end of rack 274. The fixed contacts of switch347 are connected to the two field windings of actuator 276.

There is one additional actuator 361 in the control circuit illustratedin FIG. 16 that does not perform a mechanical function in the machinebut operates only as a control element for programming the sequence ofoperations carried out by the machine. Program actuator 361 comprises asmall electrical motor having field windings 362 and 3&3 that areconnected to each other, the common terminal of the windings beingreturned to system ground. A capacitor 364 is connected across the windings 362 and 363. The rotor 335 of the motor drives a program shaft 366that actuates a series of single-pole switches 371 and 373-382 and adouble-pole switch 372. Switches 371-382 may, for example, compriseindividual cam actuated switches, the operating cams for the switchesall being mounted upon the shaft 366 of actuator 361.

The control circuit of FIG. 16 is energized from an appropriate ACsupply generally indicated by the input conductors 384 and 385.Conductor 384 is taken as the hot conductor and conductor 335 is shownas grounded. It should be understood, however, that an earth ground isnot required and that an ungrounded system may be utilized if desired.

Conductor 384 is connected through a normally closed emergency stopswitch 336 and through a manually operated switch 337 to one terminal ofeach of the drill and router motors. The other terminal of each of themotors is returned to system ground. Thus, by closing switch 387, themachine operator energizes all of the drills and routers and thesedevices are maintained in continuous operation while the machine is inuse.

Power conductor 38 iis also connected through the emergency stop switch385 and through the two sides of a normally open momentary-contactdouble-pole start switch 388 to the movable contacts 337 and 312 ofactuators 227 and 124, respectively. Power conductor 384 is alsoconnected to a buss 392 that is connected to the input terminal 393 forthe program actuator 361. Moreover, a direct connection is taken frombuss 384 to one terminal of each pole of the program control switch 372.

Program switch 371 is closed when program actuator 361 is in its initialor home position whereas the remaining switches 372-382 controlled bythis actuator are held open in that position of the actuator. Oneterminal of switch 371 is connected to the *buss 332 and the otherterminal of this switch is connected to the normally open contact ofswitch 338 of actuator 227. In the following description of the actuatorswitches, the expressions normally open and normally closed refer to theoperating conditions of the switch Contacts when their actuators are intheir respective home positions, as illustrated. The normally closedcontact of actuator switch 308 is connected to one movable contact 394of a double-pole double-throw reversing switch 395. For normal operationof the machine, contact 394 of switch 395 is connected to a fixedcontact which is in turn electrically connected to winding 302 ofactuator 227. Operation of the reversing switch 395 to its alternateposition shifts contact 394 to engagement with a second fixed contactwhich is connected to the other winding 303 of actuator 227.

The reversing switch 395 includes a second movable contact 395. Fornormal operation, contact 396 engages a fixed contact connected to onewinding of actuator 124 but upon actuation of switch 395 is moved to analternate position in which it engages a fixed contact connected to thesecond winding of the actuator motor. Movable contact 396 iselectrically connected to the normally closed contact of switch 313 ofactuator 124. Contact 312, when moved to its alternate position, engagesa normally open contact that is connected back through the programswitch 373 to buss 392.

Program switch 372, as noted above, has one terminal of each poleconnected directly to the power line 384. The other terminals of thisswitch are connected, respectively, to the two movable contacts 306 and311 of switches 300 and 310 in actuators 227 and 124. The normallyclosed contact of switch 300 is connected to the buss 392. The normallyopen contact of switch 308 is connected to the movable contact 394 ofreversing switch 395. The movable contact 311 of switch 310 in actuator124, on the other hand, is maintained in engage'ment with a fixedcontact that is open-circuited when the actuator 124 is in its homeposition. The normally open contact of switch 310 is electricallyconnected to the movable contact 396 of the reversing switch.

One terminal of each of program switches 374, 376, 377 and 379-382 isconnected to a buss 398. Buss 398, in turn, is connected to the manualswitch 387 utilized to actuate the drill and router motors and hence iscontinuously energized during operation of the machine. The otherterminal of switch 374 is connected to the movable contact 315 of switch318 in actuator 14-1. Similarly, the second terminal of switch 376 isconnected to the movable contact 322 of switch 323 in router actuator168. The normally closed contact in switch 318 is connected to the fieldwindings of the actuator. The normally open contact of switch 318 isconnected to conductor 392. A similar arrangement is used in actuator158. That is, the normally closed contact of switch 323 is connected tothe field windings of the actuator. The normally open contact of switch323 is connected to conductor 392.

The normally closed fixed contact of switch 317 is electricallyconnected to the buss 392. The normally open contact of switch 317 isconnected to the normally closed fixed contact of switch 318 and back tothe field windings of the actuator. Similarly, the normally closed fixedcontact of switch 328 in actuator 168 is connected to the buss 392 andthis is also true of the normally closed contact of switch 327 inactuator 151. The normally open fixed contact of switch 320 is connectedto the normally closed contact of switch 323, in actuator 168. Thenormally open contact of switch 327 in actuator 151 is connected to thenormally closed fixed contact of switch 328 in the actuator and is alsoconnected to the field windings of the actuator motor.

The movable contact 321 of switch 320 in actuator 168 is connectedthrough program switch 377 to the buss 398. Similarly, the movablecam-actuated contact 325 of switch 327 in actuator 151 is connectedthrough the program switch 379 to buss 398. The corresponding contact inactuatcr 141, contact 315, on the other hand, is connected through theprogram switch 375 to the normally closed fixed contact of switch 350 incylinder drill actuator 276, the movable contact 351 of this switchbeing returned to buss 398. The switch connections for the threeretarder actuators are completed by connecting the movable con tact 326of switch 328 in actuator 151 in a circuit that extends to the programswitch 378 and from that switch to the normally closed contact of switch340, the movable contact 341 of the latter being connected back toconductor 398.

The connections for the strike drill actuator 206 are somewhat simplerthan for the other positioning actuators. The movable contact 331 of thecam controlled switch 338 in this actuator is electrically connected tothe field windings of the actuator motor. The normally closed fixedcontact of this switch is connected through program switch 380 to buss398. The normally open contact of the same switch is directly connectedto buss 398.

The energizing circuits for the field windings 332 and 333 of bolt drillactuator 261 start with program control switch 381. Thus, switch 381connects buss 398 to the movable contact 343 of the single-poledouble-throw switch 337 in the energizing circuit of the actuator. Afurther connection is made from switch 381 to the normally open contactof the cam-actuated switch 340 in this actuator. A corresponding circuitarrangement is used for cylinder drill actuator 276, program switch 382being connected to the movable contact 353 in the switch 347 thatenergizes the actuator windings and to the normally open fixed contactof the cam-actuated switch 350 controlled by the actuator.

In considering operation of the control circuit of FIG. 16, it should beunderstood that the switching devices of the control apparatus are inthe illustrated positions at the start of a machine cycle. When themachine operator has loaded a door and a pair of jambs into the machine,he first closes switch 387 to energize the drill and router motors andto energize buss 398 if this has not already been done. The next step isto close start switch 388. Upon closing of this switch, lockset clampactuator 227 is energized through a circuit beginning at buss 384 andextending through switches 386 and 388 to the normally closed contact ofswitch 308 and from switch 308 through switch 394 to the field winding302 of the actuator. A similar operating circuit is established for thehinge clamp actuator 124, extending from switch 388 through switches 313and 395 to the field winding of the actuator motor. Thus, the locksetclamp actuator 227 and the hinge clamp actuator 124 are both energized,and each drives its operating shaft through an angle of The rotationalmovement of shaft 228 of actuator 227 breaks the energizing circuit forthe actuator after shaft 228 has rotated through one-half revolution,since cam 305 then engages the movable contact 307 of switch 308 andopens the operating circuit at this switch. Similarly, the operatingcircuit for hinge clamp actuator 124 is interrupted after one-halfrevolution of the actuator shaft by the opening of the normally closedcontacts of switch 313.

During the initial portion of the operating cycle of the machine, theoperator is requiredto hold start switch 388 closed to assureenergization of each of the actuators 227 and 124 until they have eachcompleted one-half revolution. This permits quick interruption ofmachine operation in the event that the operator observes that the jambsor the door are not being properly clamped in the machine. If there isan indication that clamping is not proceeding as required, and theoperator interrupts the clamping operation by releasing the start switch388 prior to completion of the operating cycles for actuators 227 and184, the door and jamb members may be partially clamped in the machine.They are readily released by the operator by actuating reversing switch395 to reverse the field connections to the actuator motors. This drivesthe actuators back to their initial positions and releases the locksetclamp and the hinge clamps to permit removal of the jambs and door fromthe machine.

Near the end of the operating cycle for actuator 227, cam 305 engagesmovable contact 307 to open the ener- 19 gizing circuit for theactuator, as described above. The cam further causes movable contact 307to close on the upper or normally open contact of switch 308 andcompletes an operating circuit, through start switch 388, to the buss392 that energizes the program actuator 361.

With actuator 361 energized, the actuator shaft 366 is driven and, aftera short period of time, opens switch 371 in the energizing circuits toactuator 227 and to buss 392. Before switch 371 opens, however, switch373 is closed by shaft 366 of actuator 361, completing an alternateenergizing circuit for buss 392 and hence maintaining actuator 361energized. This alternate energizing circuit goes from buss 392 throughswitch 373 and switch 313 and back through switches 388 and 386 to theAC. power line 384. This circuit, of course, can only be completed ifhinge clamp actuator 124 has been energized and has been operatedthrough a cycle of 180 to close contact 312 of switch 313 on thenormally open contact of the switch. Thereafter, actuator 361 is held inoperation until it opens switch 373 to break the energizing circuit forthe actuator.

From the foregoing description, it will be apparent that at thebeginning of the operating cycle the program actuator 361 can only beinitially energized through switch 371. Furthermore, the circuit throughswitch 371 can only be completed if lockset clamp actuator 227 hascompleted its initial cycle of operation and has actuated switch 308.Furthermore, the initial cycle of movement of the program switchescontrolled by actuator 361 can be completed only if the energization ofthe control actuator is continued after switch 371 has opened as aresult of completion of an alternate operating circuit through switch373. This alternate or second energizing circuit for the programactuator 361 is dependent upon the completion of the hinge clampoperating cycle by actuator 124, since the circuit extends throughswitch 313 in that actuator. Accordingly, the initial stage of operationof control actuator 361 is dependent upon complete functioning of thelockset clamp mechanism controlled by actuator 227 and of the hingeclamp mechanism controlled by actuator 124. This prevents the initiationor completion of any drilling or routing operations unless and until thedoor and the jambs are fully and properly clamped in the machine.

Just before program switch 373 is opened to interrupt continuingoperation of the program actuator 361, program switch 374 closes.Closing of this switch completes an operating circuit for the firstrouter actuator 141, the circuit extending from buss 398 through switch374 and through the normally closed contact of switch 318 to the fieldwindings of the actuator motor. When thus energized, actuator 141 drivesshaft 139 through one-half revolution, at which time the actuator cam314 engages movable contact 316 and opens switch 318. During this cycleof operation of actuator 141, the three routers for forming the hingereceptacles in the door and in the hinge jamb are advanced into contactwith the work and the routing operation is initiated as described above.

Upon completion of the half-revolution cycle of actuator 141, asdescribed above, movable contact 316 of switch 318 is brought intoengagement with the normally open fixed contact of the actuator. Thiscompletes an operating circuit for program actuator 361, the circuitextending from buss 392 through switch 318 and program switch 374 tobuss 398. Accordingly, the program actuator 361 resumes operation androtates control shaft 366 until program switch 37 4 is subsequentlyopened.

Just before program switch 374 opens, program switch 376 closes. Thisenergizes router actuator 168 through a circuit beginning at buss 398and extending through switch 376 and switch 323 to the actuator motor.Actuator 168 is driven through an operating cycle in which shaft 169 isrotated 180, moving the routers upwardly as described above. Moreover,the 180 rotation of shaft 169 rotates cam 319 and, at the end of thecycle, opens the energizing circuit for the actuator by disengagingmovable contact 20 322 of switch 323 from the normally closed contact ofthe 'switch. Actuation of switch 323 also is effective to again completean energizing circuit for program actuator 361, this circuit extendingfrom buss 398 through switches 376 and 323 to the program actuator buss392.

The resultant further energizationof program actuator 361 drives theprogram shaft 366 until program switch 376 is opened to interrupt theoperating circuit. Before switch 376 opens, switch 378 closes to affordan energizing circuit for actuator 151. The energizing circuit for therouter actuator 151, beginning at the router motor, extends through thenormally closed contacts of switch 323 and through switch 378 to thenormally closed contacts of switch 340 in the bolt drill actuator 261and from switch 340 back to the buss 398. Actuator 151 is operatedthrough a rotational cycle to drive the routers horizontally, asdescribed above. At the end of one-half revolution of the actuator shaft152, the cam 324 actuates switch 328 to interrupt the energizing circuitfor the actuator and to complete an energizing circuit for programactuator 361 through the normally open contacts of switch 328, which arenow closed.

With program actuator 361 again energized, the program shaft 366 isadvanced until switch 378 opens. Just prior to the opening of programswitch 378, switch 377 is closed to complete an operating circuit frombuss 398 to the movable contact 321 of switch 320 in router actuator168. Since the router actuator has been operated through ahalf-revolution cycle from the position shown in the drawing, movablecontact 321 is closed upon the normally open contact of switch 320 withthe result that an operating circuit is completed to the actuator motor.Accordingly, actuator 168 is again energized and rotates shaft 169through an additional half-revolution cycle, back to its originalposition, driving the routers downwardly to their starting level. Uponcompletion of this cycle of actuator 168, switches 320 and 323 arereturned to their initial operating conditions as illustrated, theenergizing circuit for the actuator being broken at switch 320. Thereturn of switch 320 to its original condition completes a newenergizing circuit for program actuator 361, the circuit extendingthrough program switch 377 (now closed) and switch 320.

With the program actuator again energized, program shaft 366 is rotateduntil switch 377 is opened, de-energizing the program actuator. Shortlybefore switch 377 opens, switch 379 is closed to energize the horizontalrouter actuator 151. The energizing circuit for actuator 151 extendsfrom buss 398 through switch 379 to switch 327, the movable contact 325of switch 327 now being closed upon its upper or normally open contactand hence completing a circuit to the actuator motor. Accordingly,actuator 151 is driven through an operating cycle of onehalf revolutionreturning to the position illustrated in the drawing. When this cycle iscompleted, the energizing circuit for actuator 151 is broken at switch327 and a new energizing circuit for the program actuator 361 isestablished through this switch and through switch 379.

The program actuator 361 again advances control shaft 366, remaining inoperation until program switch 379 is opened. Just before switch 379opens, program switch 375 is closed to complete an operating circuit forthe router actuator 141 that controls advancement and retraction of therouters. Thus, closing of switch 375 energizes actuator 141 through anoperating circuit that extends from the actuator motor to the uppercontact of switch 317, which is noW closed upon movable contact 315, andthrough switches 375 and 350 to the buss 398.

Router actuator 141 is driven through an operating cycle of 180,returning to the initial operating condition illustrated in FIG. 16.Upon completion of the halfrevolution cycle, the energizing circuit forthe actuator is interrupted at switch 317 and a further energizingcircuit is established for program actuator 361 through the contacts ofswitch 317 and through program switch 375.

With program actuator 361 energized through switch 375, program shaft366 is again rotated until switch 375 is opened. Shortly before switch375 opens, switch 372 closes. The closing of program switch 372establishes operating circuits for each of the clamp actuators 227 and124 through the switches 300 and 310, respectively, since both switchesare in their alternate operating conditions with the movable switchcontacts engaged with the upper normally open contacts. With the twoclamp actuators energized, the clamp mechanisms are driven back toreleased condition as described above, releasing the doors and the jambsso that they may be removed from the machine by the operator. Duringthis interval, the program actuator 361 is not energized; however, uponcompletion of the half-revolution cycle of either of the clampactuators, the program actuator is again energized through switch 372and through either one of switches 300 and 316.

Program actuator 361 remains energized and continues to rotate programshaft 366 until switch 372 is opened to interrupt the energizing cyclefor the actuator. Shortly before this occurs, switch 371 is closed,restoring the program mechanism to its original condition. That is, whenprogram switch 372 opens, the apparatus is back at its home positionready for the next machining operation.

Early in the operating cycle of the machine, at a time when programswitch 373 is closed, program switch 3% closes by operation of programshaft 366. Closing of switch 380 establishes an operating circuit forthe strike drill actuator 206, this circuit extending from buss 398through switch 380 and through the normally closed con tacts of switch33h to the actuator motor. Shortly after actuator 266 starts inoperation, rotation of the actuator shaft releases movable contact 331of switch 331), opening the original energizing circuit but completingan alternate energizing circuit for the actuator through the other fixedcontact of switch 330, this alternate energiz' ing circuit beingindependent of program switch 330. Thereafter, actuator 2196 operatesthrough an operating cycle in which the actuator shaft is rotatedthrough a full revolution to first advance the drill 203 (FIG. 12) anddrill the strike receptacle in the lock jamb of the door, and then toretract the drill to its original condition. When the shaft of actuator2&6 has completed a full revolution of 360 it again actuates switch 331to interrupt the operating circuit for the actuator. By this time,program switch 380 has again opened and the strike drill actuator 206 isnot again energized until the next operation of the machine.

At about the same time that program switch 380 closes, that is to saywhile program switch 373 is closed, program switch 331 is also closed byoperation of program shaft 36-6. The closing of switch 381 completes anenergizing circuit 'for bolt drill actuator 261, this circuit extendingfrom buss 398 through the reversing switch contact 343 to the one coil333 of the actuator motor. Consequently, rotor 335 starts to rotate,driving spur gear 262 and moving rack 263 to the right from its initialposition as shown in FIG. 16. The movement of rack 263 also beginsadvancement of the lock bolt drill 266 as described hereinabove (FIGS.13 and 15).

With the initial movement of rack 263, switch 341) is actuated, throughspring 339, disengaging movable contact 341 from the normally closedcontact of the switch and engaging that contact with the normally opencontact of the switch. Consequently, when program switch 331subsequently opens, actuator 261 remains energized through theconnection from buss 398 to movable contact 341 of switch 340 and fromswitch 340 to the reversing switch contact 343.

When rack 263 reaches the extreme right-hand limit of its travel,abutment 344 strikes lever 342 and actuates the reversing toggle switch337 for actuator 261, displacing contact 343 from its initial positionand closing this contact on the motor field terminal connected to coil332. This reverses the direction of rotation of the actuator motor andbegins to drive rack 263 back to the left, as seen in FIG. 16, towardits initial position. The reversal in direction of rotation of theactuator motor thus begins withdrawal of the drill shaft from the boltaperture that has been drilled in the door. When rack 263 reaches theoriginal position shown in the drawing, the energizing circuit foractuator 261 is interrupted at switch 340 since movable contact 341returns to its original position. Reversing toggle switch contact 343may simultaneously return to its original position, or this switch mayfunction immediately at the beginning of the next succeeding cycle ofoperation of actuator 261.

Operation of cylinder drill actuator 276 is essentially similar to thatdescribed above for lock 'bolt drill actuator 261, but occurs later inthe machine cycle. Thus, program switch 382 closes during the period ofmachine operation in which program switch 378 is closed. This energizesactuator 2'76 and brings the advancing movement of cylinder drill 277 todrill the cylinder aperture 55 in the door (FIG. 15), as spur gear 275drives rack 274.

In response to the initial movement of rack 274, switch 35% (FIG. 16) isoperated from its initial position as shown in the drawing to completean alternate energizing circuit for actuator 276 that is dependent ofcontrol switch 382. When rack 274 reaches the end of its travel, toggleswitch 3 37 is actuated, the direction of rotation of the actuator motoris reversed, and the drill is withdrawn from the door, the reversal ofthe actuator motor driving rack 274 back to its initial position. Whenthe rack reaches the initial position as shown in FIG. 16, switch 351)is again actuated back to its original operating condition. As beforetoggle switch 347 may return to its original position simultaneouslywith operation of switch 359 or may be actuated immediately at thebeginning of each cycle.

The two lockset drill actuators 261 and. 276 are interlocked with therouter actuators 151 and 141, respectively, to prevent any possibilitythat the routing operations will be completed and the workpiece clampsreleased when the lockset drilling operations are not finished. Thus,during the time interval in which the lock bolt drill actuator 261 isenergized, the initial operating circuit for router actuator 151,through program switch 378, cannot be completed because the circuit isopen atv switch 34-0. Stated differently, the full cycle of operationfor bolt drill actuator 261 must be completed and switch 341 must returnto its original operating position before the hinge router actuator 151can 'be energized to perform the initial horizontal movement of therouters. Furthermore, under these conditions it is not possible tocomplete the energizing circuit for program actuator 361 describedhereinabove that must be stablished through switch 378 at one stage ofthe machine program. Accord ingly, it is seen that the machine programcannot be completed unless and until lock bolt drill actuator 261performs the operations necessary to drill the bolt aperture in thedoor.

The same condition applies with respect to program switch 375 and theenergizing circuit for actuator 141 that is employed to withdraw therouters from working position. Thus, when switch 375 closes, in thecourse of the machine program, it is efiective to energize routeractuator 141 only if the cylinder drilling operation has been completedby actuator 276 and actuator 276 has returned to its initial operatingposition with switch 350 in the illustrated position. Again, continuingoperation of actuator 361 and completion of the machine control programis dependent upon an energizing circuit that extends through switch 375and through switch 350 of actuator 276 so that the program cannot befinished unless the cylinder aperture has been drilled into the door.

The interlocking circuits afforded by switches 340 and 3511 do not delaythe completion of the routing opera- 23 tions and do not add to thetotal time required for the normal machine program. The normal timing ofthe machine is such that the drilling operations taking place at thelockset drill head 62 of the machine are completed before the time whenthe interlocked router actuators would ordinarily be energized. All thatthe interlock connections do is to assure completion of the completemachine program, including the lockset drilling operations, before theprogram actuator 361 completes its cycle and releases the workpiecesfrom their clamped relation ship in the machine. The time required forthe lockset drilling operations (and for the drilling of the strikerplate receptacle) is substantially shorter than the time required forthe routers to complete the hinge receptacles so that there is an ampletime margin with respect to completion of the machine program andrelease of the clamps holding the door and the jambs in the machine.

From the foregoing description, it will be apparent that the automaticrouting and drilling machine 60 of the present invention effectivelyforms the hinge plate receptacles, the lockset apertures, and thestriker plate receptacle in a matching door and pair of door jambs in asingle machine operation. The machine may be quickly and convenientlyadjusted to accommodate a wide variety of standardized door widths,lengths, and thicknesses and may be adjusted with equal flexibility toprovide for fabrication of left-hand or right-hand door assemblies. Noneof the components of the door assembly are moved during the drilling orrouting operations. The door and jambs are easily and quickly loadedinto processing position and there are no drills or routers locatedabove the work to interfere with the machine operator. The ad justmentsrequired in the routing mechanism to accommodate the direction ofhanging of the door are quite simple and are easily effected and theminor adjustment provided for changes in door height is also easilyaccomplished. The machine inherently provides precision alignment of thelock bolt receptacle in the door and of the striker plate receptacle inthe lock jamb of the door assembly. Nevertheless, the machine is quitesimple and inexpensive, though capable of a relatively high output,

Hence, while preferred embodiments of the invention have been describedand illustrated, it is to be understood that they are capable ofvariation and modification.

I claim:

1. An automatic routing machine for single-operation routing anddrilling of a door, a hinge jamb and a lock jamb, for hinges and alockset, comprising:

means for supporting a door in a given plane;

means for supporting a hinge jamb in alignment with one longitudinaledge of said door but in a plane normal to the plane of said door;

means for supporting a lock jamb in parallel alignment and in the sameplane with said hinge jamb;

a plurality of routers;

means for actuating said routers to rout said hinge jamb and said onelongitudinal edge of said door in a single operation to afford aplurality of hinge receptacles therein;

a first drill for drilling the other longitudinal edge of said door toafford a lockset bolt receptacle therein;

a second drill for drilling said lock jamb to afford a strike receptacletherein;

fixed adjustable mounting means for mounting said drills with their axeslocated in a single fixed drill plane normal to the planes of said doorand said jambs but permitting adjustment of said drills within saiddrill plane;

and stop means for locating said door and said jambs at either one oftwo different longitudinal positions to provide for routing and drillingof said door and said jambs for either right-hand or left-hand mountingwithout changing the location of said drill plane.

routing and drilling of a door, a hinge jamb and a lock jamb, for hingesand a lockset, comprising:

means for supporting a door with one side surface in a given horizontalplane;

means for supporting a hinge jamb in flush alignment with onelongitudinal edge of said door and in a vertical plane above said door;

means for supporting a lock jamb in parallel fiush alignment and in thesame plane with said hinge jamb and above said hinge jamb;

a plurality of routers mounted at one side of said vertical plane on acommon support adjacent the conjunction of said hinge jamb and said oneedge of said door;

means for actuating said routers to rout said hinge jamb and said oneedge of said door in a single operation to afford a plurality of hingereceptacles therein;

a first drill for drilling the other longitudinal edge of said door toafford a lockset bolt receptacle therein;

a third drill for drilling the upper portion of said lock jamb from saidone side of said vertical plane to afford a strike receptacle therein;

a second drill for drilling said door normal to the principal plane ofthe door to afford a cylinder receptacle intersecting said lockset boltreceptacle;

fixed adjustable mounting means for mounting all of said drills withtheir axes located in a single fixed vertical drill plane normal to theplanes of said door and said jambs but permitting relative adjustment ofsaid drills within said drill plane;

and stop means for locating said door and said jambs at either one oftwo different longitudinal positions to provide for routing and drillingof said door and said jambs for either right-hand or left-hand mountingwithout changing the location of said drill plane.

3. An automatic routing machine for single-operation routing anddrilling of a door, a hinge jamb and a lock jamb, to receive hinges anda lockset, said machine being of substantially T-shaped configurationwith the cross-bar of the T comprising a routing head and the leg of theT comprising a lockset drilling head, comprising:

means for clamping a door in said machine in a given plane, with onelongitudinal edge of said door clamped against said routing head andwith a medial portion of the opposite longitudinal edge clamped againstsaid lockset drilling head;

means for clamping a hinge jamb and a lock jamb against said routinghead in flush alignment with said one longitudinal edge of said door butin a plane normal to the plane of said door and with said lock jambspaced from said door by said hinge jamb;

electrical actuating means for actuating the aforesaid clamping meansbetween clamping and released positions;

a plurality of routers mounted within said routing head;

means for actuating said routers simultaneously to rout said hinge jamband said one longitudinal edge of said door in a single operation toafford a plurality of hinge receptacles therein;

a first drill, mounted in said lockset drill head, for drilling theother longitudinal edge of said door to afford a lockset bolt receptacletherein;

a second drill, mounted in said routing head, for drilling said lockjamb to afford a strike receptacle therein, said drills being mountedwith their axes parallel to each other and located in a common fixedplane normal to the planes of said door and said jambs;

and stop means for locating said door and said jambs at either one oftwo different longitudinal positions to provide for routing and drillingof said door and said jambs for either right-hand or left-hand mountingwithout changing the location of said drill plane.

4. An automatic routing machine for single-operation routing anddrilling of a door assembly comprising, as components, a door, a hingejamb and a lock jamb, said 2. An automatic routing machine forsingle-operation machine being of substantially T-shaped configurationwith the cross-bar of the T comprising a routing head and the leg of theT comprising a lockset drilling head, comprising:

retaining means for retaining said door assembly components in saidmachine with one longitudinal edge of said door extending along saidrouting head and with said jambs in parallel flush alignment with saidone edge of said door but normal thereto, said hinge jamb beinginterposed between said lock jamb and said door;

first clamping means for clamping said jambs and said door, at saidrouting head, both vertically and horizontally;

second clamping means for clamping the medial portion of the oppositelongitudinal edge of said door, vertically and horizontally, at saidlockset drilling head;

a plurality of routers mounted within said routing head;

means for actuating said routers simultaneously to rout said hinge jamband said one longitudinal edge of said door in a single operation toafford a plurality of hinge receptacles therein;

first and second lockset drills, mounted in said lockset drill head, fordrilling said door at its other longitudinal edge to afford intersectinglockset bolt and cylinder receptacles therein;

a third drill, mounted in said routing head, for drilling said lock jambto afford a strike receptacle therein, said drills all being mounted ina fixed lockset drill plane normal to said jambs and aligned with theleg of said T;

and stop means for locating said door and said jambs at either one oftwo different longitudinal positions to provide for routing and drillingof said door and said jambs for either right-hand or left-hand mountingwithout changing the location of said drill plane.

5. An automatic routing machine for single-operation routing anddrilling of a door assembly comprising, as components, a door, a hingejamb and a lock jamb, said machine being of substantially T-shapedconfiguration with the cross-bar of the T comprising a routing head andthe leg of the T comprising a lockset drilling head, comprising:

retaining means for retaining said door assembly components in saidmachine with one longitudinal edge of said door extending along saidrouting head and with said jambs in parallel flush alignment with saidone edge of said door but normal thereto, said hinge jamb beinginterposed between said lock jamb and said door; first clamping meansfor clamping said jambs and said door, at said routing head, bothvertically and in a direction parallel to the plane of said door; secondclamping means for clamping the medial portion of the oppositelongitudinal edge of said door, vertically and laterally, at saidlockset drilling head; clamp actuating means for actuating the aforesaidfirst and second clamping means between clamping and released positions;a plurality of routers mounted within said routing head;

router actuating means for actuating said routers simultaneously to routsaid hinge jamb and said one longitudinal edge of said door in a singleoperation over a given time interval to afford a plurality of hingereceptacles therein;

a first drill, mounted in said lockset drill head, for drilling theother longitudinal edge of said door to afford a lockset bolt receptacletherein;

a second drill, mounted in said routing head, for drilling said lockjamb to afford a strike receptacle therein, said first and second drillsbeing mounted with their axes parallel to each other and to the plane ofsaid door and located in a fixed lockset drill plane normal to saidjambs;

a third drill mounted in said lockset drill head, with the axis of saidthird drill normal to the plane of said door but within said locksetdrill plane, for drilling said door to afford a lockset cylindertherein;

drill actuating means for actuating said drills to drill saidreceptacles during said time interval in which said routers areactuated;

said clamp, router and drill actuating means each comprising anelectrical motor having a mechanical connection to the device actuated;

and stop means for locating said door and said jambs at either one oftwo different longitudinal positions to provide for routing and drillingof said door and said jambs for either right-hand or left hand mountingwithout changing the location of said drill plane.

6. An automatic routing machine for single-operation routing anddrilling of a door assembly comprising, as components, a door, a hingejamb and a lock jamb, said machine being of substantially T-shapedconfiguration with the crossbar of the T comprising a routing head andthe leg of the T comprising a lockset drilling head, comprising:

retaining means, including stop means for engaging the ends of said doorassembly components to retain said door assembly components in twodifferent longitudinal alignments, for left-hand and right-hand doorsrespectively, in said machine, with the door horizontal and onelongitudinal edge of said floor extending along said routing head, andwith said jambs in parallel flush alignment with said one edge of saiddoor but vertically aligned, and with said hinge jamb interposed betweensaid lock jamb and said door in both alignments,

said components being displaced longitudinally by a given distance D, inopposite directions, from a lockset drill plane parallel to the leg ofthe T and perpendicular to the door and the jambs;

first clamping means for clamping said j'ambs and said door at saidrounting head, both vertically and horizontally;

second clamping means for clamping the medial portion of the oppositelongitudinal edge of said door, vertically and horizontally, at saidlockset drilling head;

a plurality of routers mounted within said routing head;

means for actuating said routers simultaneously to rout said hinge jamband said one longitudinal edge of said door in a single operation toafford a plurality of hinge receptacles therein;

a first drill, mounted in said lockset drill head, for

drilling the other longitudinal edge of said door horizontally to afforda lockset bolt receptacle therein;

a second drill, mounted in said routing head, for drilling said lock jamhorizontally to afford a strike receptacle therein; and

a third drill, mounting in said lockset drill head, for

drilling the door vertically to afford a. lockset cylinder receptacletherein communicating with said bolt receptacle, all of said drillshaving their axes located in said lockset drill plane.

7. An automatic routing machine for single-operation routing anddrilling of a door assembly comprising, as

components, a door, a hinge jamb and a lock jamb, said machine being ofsubstantially T-shaped configuration with the cross-bar of the Tcomprising a routing head and the leg of the T comprising a locksetdrilling head, comprising:

retaining means for engaging the ends of said door assembly componentsto retain said door assembly components in two different alignments, forleft-hand and right-hand doors respectively, in said machine, with thedoor horizontal and one longitudinal edge of said door extending alongsaid routing head, and with said jambs in parallel flush alignment withsaid one edge of said door but vertically aligned, and with said hingejamb interposed between said lock jamb and said door in both alignments,

11. AN AUTOMATIC DRILLING MACHINE FOR DRILLING A DOOR TO RECEIVE ALOCKSET, COMPRISING: MEANS, COMPRISING A T-SHAPED FRAME FOR SUPPORTING ADOOR IN A GIVEN HORIZONTAL PLANE WITH ONE LONGITUDINAL EDGE OF SAID DOOREXTENDING ALONG THE CROSS-BAR OF THE T AND THE OTHER LONGITUDINAL EDGEINTERSECTING THE LEG OF THE T; A FIRST CLAMPING DEVICE, MOUNTED ON THELEG OF SAID FRAME ADJACENT SAID OTHER LONGITUDINAL EDGE OF SAID DOOR,FOR CLAMPING SAID DOOR AGAINST SAID FRAME TO PREVENT VERTICAL MOVEMENTOF SAID DOOR; A SECOND CLAMPING DEVICE, MECHANICALLY CONNECTED TO ANDACTUATED BY SAID FIRST CLAMPING DEVICE, FOR ENGAGING SAID OTHERLONGITUDINAL EDGE OF SAID DOOR AND CLAMPING SAID DOOR AGAINST THECROSS-BAR OF THE T TO PREVENT HORIZONTAL MOVEMENT IN SAID PLANE NORMALTO SAID CROSS-BAR; A DRILL CARRIAGE, MOUNTED ON THE LEG OF SAID FRAMEFOR MOVEMENT TOWARD AND AWAY FROM SAID ONE EDGE OF SAID DOOR; A FIRSTDRILL MOUNTED ON SAID DRILL CARRIAGE, FOR DRILLING SAID ONE EDGE OF SAIDDOOR HORIZONTALLY TO FORM A LOCKSET BOLT RECEPTACLE THEREIN; CONNECTINGMEANS FOR ADJUSTABLY CONNECTING SAID DRILL CARRIAGE TO SAID SECONDCLAMPING DEVICE TO LIMIT MOVEMENTS OF SAID DRILL CARRIAGE TO APREDETERMINED RANGE AND THEREBY ADJUST THE BACKSET OF SAID BOLTRECEPTACLE; AND A SECOND DRILL, MOUNTED ON SAID DRILL CARRIAGE ANDCONNECTED TO SAID CONNECTING MEANS, FOR DRILLING A TRANSVERSE LOCKSETCYLINDER RECEPTACLE, COMMUNICATING WITH SAID BOLT RECEPTACLE, IN SAIDDOOR.